Prefabricated door package assembly



May 19, 1959 YL. L; LESTER, JR 2,887,219

PREIF'ABRICATED DOR PACKAGE ASSEMBLY Filed March 28, 1955 zsneets-sneet1 Avi-rvs,

United States Patent O PREFABRICATED DOOR PACKAGE ASSEMBLY Lawson L.Lester, Jr., Martinsville, Va.

Application March 28, 1955, Serial No. 497,189

8 Claims. (Cl. 20660) This invention relates generally to preformed doorand frame constructions and to the manner of packaging the same.

Of primary importance in connection with this invention is the provisionof improved means for packaging preformed door and frame constructionsand generally of means calculated to simplify the process of packagingsuch articles for shipment.

A11 object of this invention is to provide an improved combination ofcorner packing means and securing blocks which cooperate to `enable thecorner packing means to be separately applied.

Another object of this invention is to provide a combination of securingblocks and corner packing means in which the corner packing means areaixed to the securing blocks to hold a preformed door and frameconstruction in proper relationship for shipping. l

Still another object of this invention is to provide a specially formedsecuring block for use in conjunction with corner securing means,wherein the blocks are provided With grooves or notches to receivefasteners which will at once prevent movement of two parts in onedirection but will permit their ready disengagement in another directionand to provide corner securing means operable in conjunction with thesecuring blocks to preclude the disengagement of parts until such timeas the corner means themselves are removed.`

Still` another object of this invention resides in the provision ofreinforcing wedge means for the door and frame construction to rigidifythe same both during the shipping process and after installation of thepreformed construction. p p

These and other objects inherent in the invention hereinafter describedwill become apparent as the description proceeds.

Illustrativeembodiments of the invention are shown in the accompanyingdrawings but it is to be understood that this showing is illustrativeonly and is not intended to be limiting to the exact construction shownsince obviously changes `can be made both in detailed construction andarrangement of parts without forming a departure from the spirit andscope of this invention `as set forth and delined in the appendedclaims.

In the drawings:

Fig. l is a perspective view of the package unit;

Fig. 2 is an enlarged vertical section taken generally along line 2 2 inFig. l;

Fig. 3 is an enlarged horizontal section taken along line 3--3 in Fig.l;

Fig. 4 is an enlarged perspective view of one of the upper corners ofthe package unit with the corner boot removed;

Fig. 5 is an enlarged perspective of one of the lower corners of thepackage unit with the corner boot removed; and

Fig. 6 is an elevational view showing a portion of the prefabricateddoor assembly being assembled into a door opening andillustrating themanner of `using the wedges.

ice

` Referring now more particularly to the drawings, the reference numeral10 indicates the package unit generally which includes the preformeddoor and frame assembly as well as the elements cooperable therewith andaffixed with particular relation thereto to form the package adapted forshipping the door assembly.

The door and frame assembly itself consists of two side frame memberswhich are interconnected at their upper ends by a header, effecting agenerally inverted Uf shaped conguration with the door proper beinghingedly secured to one of the side frame members and cooperable withthe latch and lock mechanism on the other side frame member in aconventional and well understood manner. As will be seen most clearly inFigs. 2 and 3, the side frame members and the header each consist of apair of spaced molding strips which will be designated the inner moldingstrip 11 and the outer molding strip 12, it being understood that thesemolding stripsmay take any desired ornamental configuration. Rigidlyaixed by any suitable means `to the inner and outer molding strips 11and 12 are the inner and outer jamb sections 13 and 14. These jambsections extend at right angles to the molding strips adjacent to onelongitudinal edge thereof such as to afford an L-shapedv cross-sectionalconstruction and during normal engagement ofparts, the cross-sectionalconfiguration of the side pieces and the header is channel like asshown. The inner or free longitudinal edges of the jamb sections 13 and14 are provided with notches or grooves 15` and 16 which extendlongitudinally thereof which are of such dimension as tobe substantiallythe same width as the tongue portions 17 and 18 which are formed by thenotches so that when the parts are interengaged in a manner `indicatedin Figs. 2 and 3, the tougue portions 17 and 18 willfrictionally engagewithin the corresponding notches to effect a telescoping, overlappinginterengagement between the inner and outer molding strips 13 and 14.

The inner jamb strip 13 of both side frame members and the header isprovided with a longitudinal cut-away portion or notch 19 which extendsto and opens upon the inner edges of these jarnb strips for the purposeof receiving the door structure 20 therein and form a peripheral stopsurface 21 for the door in a manner well understood. The door isprovided with suitable `hinges 22 connecting it to the inner 1jambstrip` 13 in the manner illustrated.

The above described construction is not in itself intended to form thesubject matter of this invention, the invention residing incertainconstructions and 'arrangement of parts cooperable therewith to beutilized for the purpose of shipping` the preformed` door and framestructure such that it may arrive at its destination in a Wholesomeandintact state devoid of damage such as chipping, marring, scratchingor the like.

For the purpose of rigidifying the side frame members during shipmentand for rigidifying them during and p end 27 of the innerwedge such thatthe two together initially form a rectangular block. A single fasteningelement such as the nail 28 is driven through the outer wedge 24 andinto the inner wedge 23 to hold the outer wedge in place during shipmentand before installation. In this respect, it will be noted that as shownmost clearly in Fig. 3, the head of the fastener 28 is preferably leftgesegelt;

in such a manner that it is spaced somewhat from the outer surface ofthe wedge 24 so that it may be easily removed by claw hammer or thelike. The purpose of the fastener 28 is solely to hold the outer wedge24 in place prior to installation of the preformed assembly. Ininstalling the preformed assembly, the longitudinally separable portionsof the door frame are parted and the inner section including the molding11 and the jamb section 15 together with the door 20 are placed inapproximately the, desired position within the door opening defined inpart by the vertical studs indicated by the reference characters 29 and30. Of course, prior to the installation of this portion of the unit,the outer wedges 24 have been removed from the inner wedges. When thedoor and frame portion is in approximately the correct position, theouter wedges 24 are inserted in place in the manner shown in Fig. 6 andmay be driven downwardly in respect tc the inner wedges to tightly wedgethe preformed portion between the Vertical studding 29 and 30 andsimilar but opposite studding not shown which is cooperable with theother side of the unit. Thus, the wedge construction is not onlydesirable in connection with the packaged unit wherein it rgidiiies andstrengthensthe side frame members but also it serves the purpose ofproperly positioning the door frame and door assembly and wedging thesame in place when the unit is installed.

Asv will be evident from Fig. l, the packaged unit includes thepreviously described door and frame assembly provided at each cornerthereof with the boot members 31, 32, 33 and 34, a second mechanism forholding the door frame sections together against separation and to serveas a base to which the corner boot members are secured, and the frontand back protective sheets 35 and 36. Each of the corner boots includesa pair of spaced side wall pieces 37 and 3S which have at least twointerl secting right angular edge portions 39 and 40 and corner pieces41 and 42 joining the wall pieces along these intersecting edges in themanner shown most clearly in Fig. l with yreference to the corner boot31.

As is tor be seen most clearly in Figs. 2 and 4, a pair of securingblock members 43 and 44 are associated with each of the upper corners ofthe door and frame construction, the securing blocks being of suchlength as to extend between and abut the molding strips 11 and 12 whenthe tongue and groove connections of the jamb sections 13 and 14 arefully engaged. The lower surface of each block is cut-away as indicatedby the reference character 45 for substantially half its length toprovide clearance for the stepped relation between the jamb sectionsv13and 14. Additionally, the vertical notch 46 is provided in the side face47 of each block and the depth ofv this notch, although not critical,preferably extends to about half the thickness of the securing blocks.Further, there is another vertical notch 48 provided in each securingblock in one end face thereof such as to extend longitudinally of theblock. Fasteners 49 and 50 extend through the respective notches 46y and48 and into the respective jamb sections 13 and 14 serving to rigidlyretain the securing blocks in place when the boots 31 and 32 are placedin enveloping relation over the upper corners of the door and frameconstruction. To then maintain the corner boots in position, fasteners51 and 52 are driven through the corner pieces 41 and 42 thereof intothe securingblocks 43 and 44. Thus, a rigid, protective assemblage isprovided for the upper corners of the door and frame construction. It isto be noted that the height of each securing block is such as to spacethe upper face 51 thereof somewhat below the outer edge of the inner andouter molding strips, thus permitting the securing block fasteners 49and 50 to be driven to such as extent that their heads 52 and 53 are notcrushed into the body of the blockbut' lie outwardly thereof between theblocks and overlying'corner pieces 41 and 42. This in turn permitsyready removal of the blocks after the corner boots are removed. Also,and moreimportant, it permits the fasteners 5() to slide freely withinthe groove 48 so that once the corner boots have been removed, the jambsection 14 and its associated parts may be withdrawn and disengaged fromthe jam section 13. Thereafter, removal of the fasteners 50 will berelatively simple since they project a very substantial distance abovethe surface of the jamb section 14. Also, the securing blocks will thenpresent a free end portion projecting beyond the jamb section 13 so thatlight hammer blows 0n this free end will easily pull out the fasteners49 and free the securing blocks.

The situation relative to the lower corner boots is similar in somerespects to the upper corner boots in that securing blocks 54 areassociated with the lower portions of the side frame members. Theseblocks are fastened to the inner and outer jamb sections by means offasteners 55 and 56 which project through the vertical notches 57 and 58of blocks 54, similarly to the manner in which the previously describedsecuring blocks are fastened. If it is desired, the blocks 54 may beprovided with notches 59 on their undersurfaces to clear an associatedwedge assembly 60 disposed therebeneath and fastened to the inner jambsection in the manner previously described. Of course, the blocks 54include lower surface notches 61 to clear the step formed between thetwo jamb sections.

Secured to the lower edge of the door adjacent each corner of the doorand frame construction is a spacer block 62, securement being occasionedfor example by a pair of fasteners 63 and 64. Since the width of thespacer blocks 62 is such as to extend between the side walls of theboots 33 and 34, they project a substantial distance beyond one side ofthe door 20 so that When the corner boots 33 and 34 are removed, thespacer blocks are also easilyV removed by merely hitting them with ahammer or similar object. Fasteners 65 and 66 are driven through thecorner pieces of the boots 33 and 34, into the securing blocks 54 andspacer blocks 62 respectively, firmly securing these boots in place forshipping.

Thus it will be apparent that a simple and readily packaged unit iseffected by the construction described. It is to be noted that theprotective sheets 35 and 36 are preferably of substantially the samearea as the door and frame construction so that when the corner bootsare in place thereover, the sheets are eiectively held in place. Thesheets may be made of cardboard, plywood or any desired material and inaddition to the protective feature, they additionally serve to present acompartment 67, with door 20, within which the door hardware such aslock and knob assembly may be placed.

This is particularly useful in constructions of the same general type asshown inasmuch as the door 20 is offset to one side and cannot thereforecarry the usual knob assembly without interfering with the protectivesheet 36.

The invention above described can also be applied in windowconstructions Whereina window frame may be positioned in like manner tothe door 20 and arranged for sliding movement, swinging movement orotherwise, as desired. In this case it is desirable to provide means forassociating a screen panel with the window and for this purposelongitudinally extending strips may be applied at the top and bottom ofthe outer jamb or frame section 14 in slightly spaced relation to theedge 68 of the inner jamb section 13 so as to dene therewith slots orgrooves which will receive upper and lower marginal edge portions of thescreen frame. The strip at the top of the screen would be of greaterthickness than that at the bottom so as to provide a deeper groove atthe top such that the screen panel may be easily removed by rstinserting the upper marginal portion thereof into the relatively deepgroove and then placing the lower edge in vertical registry above thelowerv groove, whereafter when the screen panel is released and allowedto drop into the lower groove, it will be projected slightly into boththe upper and `lower grooves to thus hold the screen firmly in place.

It will be appreciated that the window unit when constructed may beformed such that the longest dimension is upright or, if desired, thelongest dimension can be horizontal. In either case, the strips forholding the screen panel in place are positioned so as to be in upperand lower relationship and they are preferably spaced from the edge 68as shown in Fig. 3, a distance slightly greater than the width of thescreen panel.

l. A packaging assembly for preformed door and frame constructionsincluding side frame members joined by a header with a door hingedlysecured to one of the side frame members, the side frame members andheader being longitudinally separable, the side frame members and headerincluding molding strips joined by jamb sections to provide achannel-like cross section, said assembly comprising corner packingmeans for each of the corners of the construction to be packaged, saidmeans including spaced side wall pieces joined along adjacent, rightangularly disposed edges by corner wall pieces, securing blocks fastenedto the jamb sections adjacent each corner of the preformed door andframe construction, said securing blocks being notched in a directiontoward one of the molding strips, with the means fastening the blocks toone of the jamb sections being disposed within the notch in each block,said corner wall pieces being secured to said securing blocks.

2. A packaging assembly for preformed door and frame constructionsincluding side frame members joined by a header with a door hingedlysecured to one of the side frame members, the side frame members andheader being longitudinally separable, the side frame members and headerincluding molding strips joined by jamb sections to provide achannel-like cross section, said assembly comprising corner packingmeans for each of the corners of the construction to be packaged, saidmeans including spaced side wall pieces joined along adjacent, rightangularly disposed edges -by corner wall pieces, securing blocksfastened to the jamb sections adjacent each corner of the preformed doorand frame construction, said securing blocks being notched in adirection toward one of `the molding strips, with the means fasteningthe blocks to one of the jamb sections being disposed within the notchin each block, fasteners projecting through said corner wall pieces intosaid securing blocks whereby to fix the corner packing means to the doorand frame construction in enveloping and protecting relation to thecorners thereof.

3. A packaging assembly for preformed door and frame constructionsincluding side frame members intcr connected by a header with a doorhingedly secured to one of said side frame members, the side framemembers and header being longitudinally separable and each includingspaced molding strips connected by telescopically joined jamb sectionsto provide a channel-like cross section, the packaging assemblycomprising means embracing the corners of the door and frameconstruction, said means including spaced side wall pieces having a pairof intersecting right angular edges and corner pieces interconnectingthe side wall pieces along said intersecting edges, and securing blocksfastened on the jamb sections and extending between the molding strips,said securing blocks being notched in a direction toward one of themolding strips, with the means fastening the blocks to one of the jambsections being disposed within the notch in each block, said cornerpieces being secured to the securing blocks.

4. A packaging assembly for preformed door and frame constructionsincluding side frame members interconnected by a header with a doorhingedly secured to one of said side frame members, the side framemembers and header being longitudinally separable and each includingspaced molding strips connected by telescopically joined jambsections toprovidea channel-like cross `section, the packaging assembly comprisingmeans embracing the corners of the door and frame construction, saidmeans including spaced side wall pieces having a pair of intersectingright angular edges andcorner pieces interconnecting the side wallpieces along said intersecting edges, and securing blocks fastened onthe jamb sections and extending between the molding strips, saidsecuring blocks being notched in a direction toward one of the moldingstrips, with the means fastening the4 blocks to one of the jamb sectionsbeing disposed `Within `the notch in each block, fasteners projectingthrough said corner wall pieces into said securing blocks whereby to fixthe corner packing means to the door and frame construction inenveloping and protecting relation to the corners thereof.

5. A packaging assembly `for preformed door and frame constructionsincluding side frame members interconnected by a header lwithva doorhingedly secured to one of said side frame members, the side framemembers and header being longitudinally separable and each includingspaced molding strips connected by telescopically joined jamb sectionsto provide a channel-like cross section, the packaging assemblycomprising means embracing the corners of the door and frameconstruction, said means including spaced side wall pieces having a pairof intersecting right angular edges and corner pieces interconnectingthe side wall pieces along said intersecting edges, and securing blocksfastened on the jamb sections and extending between the molding strips,said securing blocks being notched in a direction toward one of themolding strips, with the means fastening the blocks to one of the jambsections being disposed within the notch in each block, said cornerembracing means being secured to said securing blocks.

6. A packaging assembly for preformed door and frame constructionsincluding side frame members joined by a header with a door hingedlysecured to one of the side frame members, the side frame members andheader being longitudinally separable, the side frame members and headerincluding molding strips joined by jamb sections to provide achannel-like cross section, said assembly comprising corner packingmeans for each of the corners of the construction to be packaged, saidmeans including spaced side wall pieces joined along adjacent, rightangularly disposed edges by corner wall pieces, securing blocks fastenedto the jamb sections adjacent each corner of the preformed door andframe construction, said securing blocks being notched in a directiontoward one of the molding strips, with the means fastening the blocks toone of the jamb sections being disposed within the notch in each block,said corner wall pieces being secured to said securing blocks, and asheet of protective material disposed on each side of said door andframe construction, each sheet being of substantially the same area asthe door and frame construction and having its corner portions disposedbetween one side piece of a corresponding corner packing means and] anadjacent molding strip.

7. A packaging assembly for preformed door and frame constructionsincluding side frame members joined by a header with a door hingedlysecured to one of the side `frame members, the side frame members andheader being longitudinally separable, the side frame members andlheader including molding strips joined by jamb sections to provide anoutwardly facing channel, said assembly comprising corner packing meansfor each of the corners of the construction to be packaged, said meansincluding spaced side wall pieces joined along adjacent, right angularlydisposed edges by corner wall pieces with said side wall pieces disposedclosely adjacent the outer sides of opposite molding strips, securingblocks fastened to the jamb sections within said channel and adjacentsaid corners of the preformed door and frame construction and extendingbetween the opposed faces of the molding strips such that said moldingstrips are sandwiched between the side Wall pieces` and the securingblocks, said securing blocks being notched in a direction toward one ofthe molding strips, with the means fastening the blocks to one'of thejamb sections being disposed within the notch in each block, saidsecuring blocks underlying corresponding corner wall pieces and saidcorner wall pieces being fastened to said securing blocks.

8. A packaging assembly for preformed door and frame constructionsincluding side vframe members joined by a header with a door hingedlysecured to one of the side frame members, the sideframe members andheader being longitudinally separable, the side frame members and headerincluding molding strips joined by jamb sections to provide achannel-like cross section, said assembly comprising corner packingmeans rfor each of the corners of the construction to be packaged, saidmeans including spaced' sidewall pieces joined along adjacent,

right angularly disposed edges by corner wall pieces, y

securing blocks adjacent the upper corners of saidl frame extendingbetween the molding strips, each of said securingblocks having avertical notch in one side face thereof and a Vertical notch in one endface thereof, fasteners extending through each of said notches and intothe adjacent jamb sections for rigidly retaining the securing blocks inplace, said corner Wall pieces being secured to said securing blocks.

References Cited in the ile of this patent UNITED STATES PATENTS1,910,781 Way May 23, 1933 2,290,990 Pagel July 28, 1942 2,331,753Wohlers Oct. 12, 1943 2,489,029 Guerrant Nov. 22, 1949 2,651,814 LesterSept. 14, 1953 2,711,564 Jackson June 28, 1955 2,753,602 Ringle July 10,1956

